MEASUREMENT & ANALYTICS. Millmate thickness gauging systems Gapless gauging for aluminium strip

Transcription

1 MEASUREMENT & ANALYTICS Millmate thickness gauging systems Gapless gauging for aluminium strip

2 2 MILLMATE THICKNESS GAUGING SYSTEMS GAPLESS GAUGING FOR ALUMINIUM STRIP Millmate thickness gauging systems Imagine outstanding dependability Gauge control is crucial for modern rolling mills. Strip producers around the world have replaced their X-ray and contact gauges with ABB s Millmate Thickness Gauge (MTG) and have improved their competitiveness. The aluminium rolling mill operations at Profilglass S.p.a in Fano, Italy, has more than fifteen years of experience using Millmate Thickness Gauges Application The MTG Box Gauge is designed for use in aluminium cold rolling mills and aluminium continuous casters. In rolling mills, the MTG systems are connected to AGC systems for feedback, feedforward and massflow control. PEC Technology The MTG Box Gauge, based on PEC (Pulsed Eddy Current) technology, opens up new dimensions in aluminium strip gauging. Weak magnetic fields are used for measurement and the gauge is completely safe to use. The technology is completely insensitive to anything in the measuring zone, except the metal strip. The gauge will, therefore, measure true strip thickness, unaffected by coolant, dirt, steam, air temperature variations, etc. Since the MTG Box Gauge is material-independent, there is no need for alloy compensation and calibration. Increased mill production time In a production process running 24 hours a day, every minute of production time is precious. Thanks to its alloy independence, the MTG can increase available production time by eliminating the need to stop for standardization and calibration. The hydraulic positioning system allows the gauge to measure almost instantaneously when tension comes on, thus optimizing the strip length under thickness control. Tighter strip tolerances The ability to produce strip to tighter tolerance maximizes productivity and minimizes the costs associated with non-conforming strip. It also increases the strip producer s accessible market to include products with tighter tolerance requirements. Alloy chemistry variations that are within tolerance but affect the accuracy of X-ray gauges will not influence the alloy independent MTG Box Gauge. Neither will the harshest environmental conditions. Together with the compact design, this makes it the ideal gauge for interstand applications, thus opening up new possibilities for controlling thickness deviation. No health concerns Switching to the MTG Box Gauge from X-ray or isotope gauges eliminates health and environmental concerns as well as the inconvenience of restricted areas. This makes your plant a safer and more efficient place to work. It also means no costs for training and certification of your employees and no costs for disposing of radioactive waste material. Negligible costs for maintenance Share the experience of a virtually maintenance-free gauge with a large number of MTG users. Our robust gauge design, with no fragile or aging components, makes this possible. The MTG Box Gauge has no X-ray source or detector, no high voltage transformer, and no delicate precision mechanics. Short payback time (ROI) Each process application has potential for improvement. Add up your costs for mill downtime, non-conforming material, maintenance, spare parts, calibration and security associated with your existing X-ray, isotope or contact gauges. We can help you compare this to the cost of ownership of an MTG Box Gauge and we re sure you will find that the MTG Box Gauge offers you a short and competitive ROI.

3 M I L L M AT E T H I C K N E S S G A U G I N G S Y S T E M S G A P L E S S G A U G I N G F O R A LU M I N I U M S T R I P 3

4 4 MILLMATE THICKNESS GAUGING SYSTEMS GAPLESS GAUGING FOR ALUMINIUM STRIP MTG box gauge Opportunities you didn't know existed Due to its heavy duty construction and the stability of its measuring principle, the MTG Box Gauge can be used in locations where it is impossible for other gauges to function. 01 The Box Gauge head with holder for vertical positioning 02 Box Gauge head with calibration plates mounted on top 03 Traceable calibration plates supplied by ABB Gapless gauging The gauge consists of just one box as sensing element the Box gauge head. This unique invention introduces gapless gauging, with nothing above the pass line that can obstruct the strip passage. The gauge head can be installed below the mill table for best protection during threading, tail out and strip breaks. New control opportunities The MTG Box gauge measures accurately independent of environment. This means that it can be located closer to the rollgap than conventional gauges, or even interstand, without concern for mill coolant. Consequently, as the sensor can be placed at the very heart of the process, new levels for control of thickness errors and faster feed back can be reached. Opening for process improvements The Millmate Thickness Gauge offers substantial savings for non-ferrous strip production. Main benefits No material dependence -- Any aluminium alloy can be measured without using alloy compensation factors. No environmental influence -- Neither mill coolants nor air temperature changes have any effect on the measurement. No need for security measures -- The MTG uses a safe and environmentally friendly technology. Low signal drift -- Only two system calibrations recommended annually each done in less than 20 minutes. Fast commissioning -- Delivered calibrated and ready to use. 01 These benefits contribute to a higher material yield, higher production time, and a minimal need for maintenance.

5 MILLMATE THICKNESS GAUGING SYSTEMS GAPLESS GAUGING FOR ALUMINIUM STRIP 5 Function The MTG Box Gauge is based on PEC technology, which uses magnetic fields for measurement of strip thickness. The interaction between an applied magnetic field and the electrically conductive strip indicates thickness without influence from the material composition. The pulsed magnetic field is generated and measured by sturdy electric coils placed just below the cover plate. Since the magnetic field penetrates everything except metal, the coils can be protected by a heavy-duty fiberglass reinforced epoxy plate. Traceable thickness measurement The MTG Box Gauge is delivered thoroughly calibrated from the factory. Twelve calibration plates are supplied with the system for verification and adjustment of the complete measuring range. These calibration plates ensure that the gauge measures absolute thickness and thickness deviation according to traceable standards for many years of operation. A normal calibration interval is 6 months and only takes 20 minutes to perform. Robust design The aluminium-bronze housing has superior mechanical and chemical characteristics and provides robust protection for the gauge, making it optimal for harsh rolling mill environments. The gauge is mounted on a vertically moving frame, automatically adjusting its position to maintain an optimal measuring distance. The movement is operated with hydraulic valves

6 6 MILLMATE THICKNESS GAUGING SYSTEMS GAPLESS GAUGING FOR ALUMINIUM STRIP System concept A user-friendly design ABB offers a gauging system with outstanding dependability, opening up new opportunities to improve your competitiveness. 01 The millmate thickness gauging system is an intelligent measurement system designed for userfriendly commissioning, operation and service 02 The Settings page helps the user identify which I/O unit is connected to a certain signal Control unit The control unit is used for integration with other mill systems. It provides a choice of integration interfaces. Profibus-DP fieldbus communication Network communication via VIP, OPC DA and Modbus TCP. Discrete I/O-signals The Control unit also handles communication with the gauge. It communicates measurement data, system status, system control, error handling as well as implementing vertical position control functions. The control unit is available in either wall or floor mounting cabinets. Operator unit The application software is installed in an industrial computer. It can be combined either with a touchscreen for panel installation or with a standard office monitor. The computer and monitor can be separated by using a KVM Extender which enables a safe environment for the computer even though the monitor is placed close to the process. The HMI has a number of features including unit handling, different user access levels, and selectable languages. Air regulator The air regulator filters the air and controls air pressure in the gauge. The air is used for internal temperature control and provides over-pressure to prevent coolant, etc., from entering the gauge. 01 Network Fieldbus Control unit Hydraulic valve Mains Connection unit Hydraulic supply Mains Operator unit Air regulator Gauge head Gauge holder Compressed air

7 MILLMATE THICKNESS GAUGING SYSTEMS GAPLESS GAUGING FOR ALUMINIUM STRIP 7 System functions All system functions can be performed through the Operator unit. The Operator unit uses touchscreen technology for efficient and user-friendly operator interface. The main functions are divided into four groups Operation, Diagnostics, Service and Settings. Operation In the Operation category, the operator can read and adjust current set-ups, thickness value and status information. Thickness deviation is presented as a real-time value as well as in a trend graph. Diagnostics The diagnostics category includes functions that allow the user to see current system status, information about errors and warnings, and other vital system properties. Service The service category contains use case based actions that are service related. Calibration as well as manual control functions, are in this section. Settings In the settings category the system can be adapted to local conditions. Examples of system settings are HMI theme, full screen, language, IP addresses, etc. 02

8 8 MILLMATE THICKNESS GAUGING SYSTEMS GAPLESS GAUGING FOR ALUMINIUM STRIP System interface Solutions for system integration The MTG system can easily be connected to AGC systems, based on feedback, feedforward and massflow control. 01 Twin-roll caster 02 Box Gauge on exit side of cold rolling mill, Novelis Sierre, Switzerland The Millmate Thickness Gauge can easily be integrated with a mill control system or other higher level systems. The MTG system offers different solutions for system integration both with discrete I/O signals and communication via a network. The Operator s unit, with colour graphic touchscreen, is a user-friendly interface for manual operation and maintenance. telegrams to exchange information on measurement data, system status and system set-up. The sending procedure is cyclic and the receiving procedure reacts on incoming messages. Modbus TCP is also available for Ethernet communication. The protocol is used in the same manner as VIP. I/O-signals 20 predefined I/O signals are used for communication with mill control. 2 Analogue outputs 2 Analogue inputs 8 Digital outputs 8 Digital inputs The OPC protocol is yet another means to connect the MTG Box Gauge to higher level systems via Ethernet. The system supports OPC DA Data Access as an option. To gain access to measurement data and system set-up, a higher level computer with OPC-client functionality can communicate with the Control unit. Thickness deviation is available as a fast analogue output. Status signals and gauge position control can also be handled via I/O-signals. Network communication As a complement to I/O signals different Ethernet communication protocols are available. The Vendor Internet Protocol (VIP) uses predefined data Profibus-DP As an option, the MTG system can be equipped with a Profibus-DP slave interface for communication with the rolling mill control system. The Profibus-DP interface provides fast transfer of measurement data. It can also be used for setting up nominal thickness and for remote control of system settings and gauge movement

9 MILLMATE THICKNESS GAUGING SYSTEMS GAPLESS GAUGING FOR ALUMINIUM STRIP 9 Data MTG box gauge Data PMGG201-H Gauge head Minimum/Maximum thickness 0.5 to 8 mm (20 to 315 mil) Measured alloys Aluminium, clad aluminium and other nonferrous alloys with resistivity range nωm Repeatability ±0.05% (not better than 0.3 μm (12 μin) Accuracy 1 ±0.05% (not better than 0.5 μm (20 μin) Total accuracy 2 ±(0.05% +1.5 μm (59 μin) Total accuracy, clad measurement 3 ±(0.05% +2 μm (79 μin) Oil on strip No influence Measuring distance 15 mm (590 mil) Minimum strip width 500 mm (20 in) Min distance from strip edge 100 mm (4 in) Measuring area Ø 80 mm (3.15 in) Strip position changes > 1 mm/s / >39 mil/s ±5 mm (± 197 mil) Strip slope ±6 Gauge holder stroke length 50 mm (2.0 in) Updating time 5 ms Operation temperature +5 to +70 C (+41 to +158 F) Degree of protection IP 65 Power supply (from control unit) 24 V DC, max 3 A (48 V AC, max 5A) Weight Gauge head 22 kg (48.5 lb) Gauge holder 48 kg (105.8 lb) Size Gauge head L 352 x W 228 x H 209 mm (L 13.9 x W 9.0 x H 8.2 in) Gauge head and holder L 495 x W 228 x H 353/403 mm (L 19.5 x W 9.0 x H 13.9/15.9 in) 1 Accuracy = Accuracy after calibration, measured on a calibration plate. 2 Total Accuracy = Accuracy after calibration, measured on an arbitrarily selected plate/strip at normal mill operating conditions,i.e. with mill coolants, temperature variations, pass line variations and alloy composition variations. 3 Provided that input clad parameters are correct. 352 mm 115,5 mm 165 mm 353/403 mm 80 mm 114 mm 228 mm 495 mm

10 10 MILLMATE THICKNESS GAUGING SYSTEMS GAPLESS GAUGING FOR ALUMINIUM STRIP Data for Hydraulics Working pressure Input pressure Flow Pressure switch Pressure fluid 50 bar (725 psi) 80 to 160 bar (1160 to 2320 psi) 5 l/min (176 ozpm) 40 bar (580 psi) Mineral oils DIN (HL,HLP), Phosphate ester (HFD-R) Data for Air regulator Supply pressure 5 to 16 bar (72,5 to 232 psi) Air consumption 5 dm 3 /s (11 cfm) Air quality requirement Acc to PNEUROP Particle class 3 Particle size max 1 μm (40 μin), particle content max 5 mg/m 3 Oil content class 3 Max1 mg/m 3 Condensation class 3 Condensation at +10 C (50 F) Data for Control unit PMGA200 Operation temperature +5 to 45 C (41 to 113 F) Supply voltage 115/230 V +10/-15 % Power consumption 300 VA Wall cabinet Protection IP 64 Dimensions H 658xW 600xD 200 mm (H 25,9xW 23,6xD 7,9 inch) Floor cabinet Protection IP 54 or IP 21 Dimensions H 2225xW 700xD 600 mm (H 87,6xW 27,6xD 23,6 inch) System interface I/O 2AO, 2AI, 8DO, 8DI Network communication VIP,OPC DA, Modbus TCP Fieldbus ProfibusDP Data for Operator unit Industrial computer Supply voltage 24 VDC, 120 W via AC power adapter 100 to 240 V Protection class IP 21 Monitors 17" Panel mounted touch-screen 22" or 24" Flat screen

11 MILLMATE THICKNESS GAUGING SYSTEMS GAPLESS GAUGING FOR ALUMINIUM STRIP 11 MTG system options Aluminium clad material 01 The MTG Clad function is used to measure accurate thickness of clad aluminium with up to four liners, two on each side of the core. The MTG system measures the thickness of clad material with less error, due to variations in alloy composition and clad geometry, than an x-ray gauge. The MTG is well-known for providing materialindependent thickness measurement on homogeneous, non-ferrous strip, without the need for any alloy information. With the optional clad measurement function, the MTG measures the thickness of multi-layer aluminium clad strip with superior accuracy. The start-up and commissioning routines for the clad function are straightforward and easy to use. The need for test plates is limited. New types of clad material can easily be added, without the need for time-consuming tests and calibration procedures. Scope of supply Software for clad material measurement. PC-software for calculation of the resistivity based on the alloy compensation Clad Help Function. The built-in clad function only requires information about each clad layer s nominal thickness and resistivity. The resistivity can be determined with support functions included in the scope of supply. Data Total accuracy clad function* ±(0.05% + 2 μm) * Provided that information about clad layer parameters is correct. 01 Function overview Clad parameters Mill database MTG system R 1 28 Liner 1 Thickness (T 1 ) Liner 1 Resistivity (R 1 ) Liner 3 Thickness (T 3 ) Liner 3 Resistivity (R 3 ) Core Resistivity (R C ) Liner 4 Thickness (T 4 ) Liner 4 Resistivity (R 2 ) Liner 2 Thickness (T 2 ) Liner 2 Resistivity (R 4 ) Nom Thickness R 2 28 R 3 57 R 4 57 R C 43 T 1 3% T 2 3% T 3 6% T 4 6% Nom T Nom Thickness R i, T i Thickness calculation Clad compensation Correct Thickness

12 ABB AB Industrial Automation Measurement & Analytics Force Measurement S Västerås, Sweden Phone: We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB. Copyright 2018 ABB. All rights reserved. 3BSE082475R0001 RevD